WO2010060799A1 - Solution process for the olefins polymerization - Google Patents
Solution process for the olefins polymerization Download PDFInfo
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- WO2010060799A1 WO2010060799A1 PCT/EP2009/064976 EP2009064976W WO2010060799A1 WO 2010060799 A1 WO2010060799 A1 WO 2010060799A1 EP 2009064976 W EP2009064976 W EP 2009064976W WO 2010060799 A1 WO2010060799 A1 WO 2010060799A1
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- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
- B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
- B01J8/38—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it
- B01J8/382—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it with a rotatable device only
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- C08F6/00—Post-polymerisation treatments
- C08F6/06—Treatment of polymer solutions
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- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
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- C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08F2/00—Processes of polymerisation
- C08F2/01—Processes of polymerisation characterised by special features of the polymerisation apparatus used
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- C08F2/00—Processes of polymerisation
- C08F2/04—Polymerisation in solution
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/001—Removal of residual monomers by physical means
- C08F6/003—Removal of residual monomers by physical means from polymer solutions, suspensions, dispersions or emulsions without recovery of the polymer therefrom
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- C08F6/00—Post-polymerisation treatments
- C08F6/02—Neutralisation of the polymerisation mass, e.g. killing the catalyst also removal of catalyst residues
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- C08F6/00—Post-polymerisation treatments
- C08F6/06—Treatment of polymer solutions
- C08F6/10—Removal of volatile materials, e.g. solvents
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- C08F6/00—Post-polymerisation treatments
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- C08F6/12—Separation of polymers from solutions
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/13—Phenols; Phenolates
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00168—Controlling the temperature by indirect heat exchange with heat exchange elements outside the bed of solid particles
- B01J2208/00256—Controlling the temperature by indirect heat exchange with heat exchange elements outside the bed of solid particles in a heat exchanger for the heat exchange medium separate from the reactor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00265—Part of all of the reactants being heated or cooled outside the reactor while recycling
- B01J2208/00283—Part of all of the reactants being heated or cooled outside the reactor while recycling involving reactant liquids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00265—Part of all of the reactants being heated or cooled outside the reactor while recycling
- B01J2208/00292—Part of all of the reactants being heated or cooled outside the reactor while recycling involving reactant solids
- B01J2208/003—Part of all of the reactants being heated or cooled outside the reactor while recycling involving reactant solids involving reactant slurries
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00002—Chemical plants
- B01J2219/00004—Scale aspects
- B01J2219/00006—Large-scale industrial plants
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/005—Stabilisers against oxidation, heat, light, ozone
Definitions
- TITLE "Solution process for the olefins polymerization"
- the present invention relates to a process comprising the polymerization of ⁇ -olefms in a solution phase.
- it relates to ⁇ -olefm solution polymerization wherein the obtained polymeric solution is subjected to devolatilization in order to remove the unreacted monomers from the polyolef ⁇ n.
- a solution of a polyolefin in the reaction medium is withdrawn from the polymerization reactor.
- the reaction medium comprises the liquid monomers and optionally, depending on the ⁇ -olefm to be polymerized, an inert hydrocarbon solvent, which can be used to favor the solubility of the obtained polymer in the liquid medium.
- Highly viscous polymeric solutions are discharged from the polymerization reactor, the viscosity being generally comprised between 1000 and 100000 centiPoises.
- Butene-1 (co)polymers are well known and are preferably produced by means of solution polymerization of butene-1 in the presence of coordination catalysts, which are generally referred to as Ziegler-Natta catalysts. Butene-1 (co)polymers are mainly used in the manufacture of molded products such as pipes, packaging films, adhesives.
- the solution polymerization is generally carried out in liquid butene-1 at conditions under which a solution of polybutene-1 in butene-1 is discharged from the polymerization reactor.
- the polymerization reaction may be performed in one or more continuously stirred tank reactors or static mixer reactors (SMR).
- the bulk polymerization of butene-1 i.e. without the use of any inert hydrocarbon solvent, is feasible since polybutene-1 dissolves in butene-1 at relatively low temperatures. Furthermore, the two components of the solution perfectly mix together at the optimum working temperatures of a Ziegler-Natta or a single-site catalyst system.
- the polymerization temperature in step a) is generally kept at a value comprised in the range of from 65 to 85°C, while the pressure is generally comprised between 8 and 40 bar.
- the solution polymerization of olefins necessarily requires the successive separation of the obtained polyolefin from the unreacted monomers.
- the monomer recovery is generally carried out in a separation step wherein high temperatures, of about 150-250 0 C, are required.
- a deactivation of the catalyst residues is therefore necessary in order to avoid an undesired modification of the properties of the final polymer due to a further uncontrolled polymerization of the monomers and/or a thermal degradation of the polymer.
- the patent application WO 04/000895 describes the liquid-phase polymerization of butene-1 to produce a solution of polybutene-1 in butene-1, the polymerization being carried out in one or more stirred tank reactors.
- the polymeric solution is discharged from the polymerization reactor and is conveyed to a deactivation step of the catalyst residues, which is preferably carried out in a deactivation apparatus equipped with a sequence of mixing stages.
- a catalyst deactivator is mixed to the polymer solution, the catalyst deactivator being an organic compound having at least a hydroxy group, a boiling point higher than 150 0 C, and a ratio between the molecular weight (MW) and the number of hydroxy groups ( ⁇ OH ) comprised between 20 and 100.
- the catalyst deactivator is preferably selected from propylen glycol, dipropylen glycol, glycerol, diethylen glycol, butandiol.
- WO 05/058979 relates to the catalyst deactivation of a polymeric solution obtained by a liquid-phase polymerization of butene-1.
- This application faces the problems correlated with the high viscosity of the polymer solution to be deactivated and consequent difficulty in pursuing a homogeneous mixing of the catalyst deactivator with the highly viscous polymer solution.
- the problem is solved by using a catalyst deactivator with a high viscosity, in particular an aqueous mixture with a dynamic viscosity at 30 0 C higher than 50 cP (centiPoise) and comprising one or more organic compounds having at least a hydroxy or epoxy group.
- said aqueous mixture comprises one or more alkyldiethanolammines of formula R-N (CH 2 CH 2 OH) 2 , wherein R is an alkyl radical Ci 2 -CiS.
- R is an alkyl radical Ci 2 -CiS.
- the patent application WO 04/000891 describes a method for removing the unreacted butene-1 from a solution of polybutene in butene-1 coming from a solution polymerization reactor.
- the polymeric solution is first subjected to heating and mixing conditions, so as to form a two-phase mixture consisting of a polybutene melt and supercritical gaseous butene-1, then said two-phase mixture is transferred to a sequence of two devolatilization chambers operated at a decreasing pressure.
- both the volatilizers are operated at a high temperature, in the order of 200-220 0 C, and the second volatilizer is operated under vacuum.
- an antioxidant compound (Irganox® 1010) is added to the polymer melt discharged from the second volatilizer and is fed into a static mixer used to perform the polymer extrusion.
- the Applicant has performed further experimental work on the devolatilization method described in WO 04/000891 and has observed that, notwithstanding the deactivation of the catalyst residues upstream the devolatilization chambers, the final polymer pellets may show values of melt index (MI), polidispersity index (PI) and molecular weight distribution (MWD) substantially different from the values measured at the outlet of the polymerization reactor: as a consequence, the mechanical properties of the obtained polyolefm differ considerably from the targeted properties.
- MI melt index
- PI polidispersity index
- MWD molecular weight distribution
- the above devolatilization step may be carried out in a sequence of a first and a second devolatilization chamber.
- the polymeric solution is preferably contacted with one or more antioxidant compounds inside the first devolatilization chamber.
- the polymeric solution coming from the reactor is generally subjected to a deactivation step, wherein the polymeric solution is contacted with a catalyst deactivator, said deactivation step taking place before contacting the polymeric solution with the one or more antioxidant compounds.
- step (b) conveying the polymeric solution to a deactivation tank, where a catalyst deactivator is mixed with the polymeric solution;
- step (c) separating the produced polyolef ⁇ n from the unreacted monomers by means of a devolatilization step comprising a first and a second devolatilization chamber; the process being characterized in that one or more antioxidant compounds are added to said polymeric solution upstream the devolatilization step (c) or alternatively inside the first devolatilization chamber of step (c).
- the process of the invention is aimed to neutralize the detrimental effects due to the presence of oxygen inside the volatilization chambers of the above defined step c).
- one or more antioxidant compounds are added to the polyolefm directly inside the first volatilization chamber of step c).
- a volatilization chamber is operated in such a way that the polymer settles downwards as a "polymer melt", while the monomers and optional polymerization solvents flow upward to the top of the volatilization chamber.
- polymer melt an olefin polymer in the molten state: in spite of its very high viscosity (of about 20 x 10 6 cP), said polymer melt is still able to be pumped by means of a gear pump.
- the polymer melt collects in the lower portion of the volatilizer, while the unreacted monomers are released from the upper surface of the polymer melt, so that a high turbulence regime is established inside the polymer melt. This high turbulence contributes to mix homogeneously the antioxidant compounds with the polyolefm, so as to favor an intimate contact of the antioxidant compound with the polyolefm.
- one or more antioxidant compounds are added to the polymeric solution upstream the devolatilization step (c).
- the positive effect of the invention is the consequent reaction of these antioxidant compounds with the oxygen, which penetrates inside the volatilization chambers of step c): said reaction brings to the formation of byproducts, which differently from oxygen, do not interfere with the polymer chains of the produced polyolefm and do not modify their physical properties.
- the antioxidant compounds are added to the polymer solution downstream the deactivation step (b) and upstream the devolatilization step (c).
- the antioxidant compounds preferably used in the solution polymerization of the invention are selected from the group of sterically hindered phenols, phospithes, thioesters.
- the suitable compounds belonging to the class of sterically hindered phenols are: - tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate) methane, sold under the trademark IRGANOX® 1010;
- antioxidant compounds used in the present invention are IRGANOX®
- the above compounds are generally added to the polymer at a temperature such that the antioxidant compound is in a liquid state.
- the suitable feeding temperature is from 50 0 C to 100 0 C, preferably from 60 0 C to 90 0 C.
- the suitable amount of antioxidant compounds ranges from 300 to 2000 ppm by weight, preferably from 500 to 1200 ppm, with respect to the polyolef ⁇ n produced in the polymerization step a).
- one or more ⁇ -olefms of formula CH 2 CHR, where R is hydrogen or a hydrocarbon radical C 1-8 , are subjected to polymerization in a solution phase.
- the polymerization reaction may be performed in one or more continuously stirred tank reactors or static mixer reactors (SMR).
- SMR static mixer reactors
- a solution of a polyolef ⁇ n in the reaction medium is obtained from the polymerization reactor.
- the reaction medium comprises the liquid monomers and optionally, depending on the ⁇ -olefm to be polymerized, an inert hydrocarbon solvent, which can be used to favor the solubility of the obtained polymer in the liquid medium.
- the catalyst system used in the polymerization step may be a Ziegler-Natta catalyst system and/or a single-site catalyst system comprising an alumoxane compound as the cocatalyst.
- the alpha-olefm to be polymerized in step a) is preferably butene-1 or propylene.
- the bulk polymerization in the liquid monomer is the preferred one, without using any inert hydrocarbon solvent.
- the bulk polymerization is feasible since polybutene-1 dissolves in butene-1 at relatively low temperatures.
- the two components of the solution perfectly mix together at the optimum working temperatures of a Ziegler-Natta or a single-site catalyst system.
- the polymerization temperature in step a) is generally kept at a value comprised in the range of from 65 to 85°C, while the pressure is generally comprised between 8 and 40 bar.
- the residence time of the liquid inside the reactor is generally comprised between 30 minutes and 4 hours, preferably between 2 and 3 hours.
- step (a) is carried out in liquid monomer, preferably together with a polymerization solvent selected from a paraff ⁇ nic, isoparaffinic, naphtenic, or aromatic hydrocarbon solvent, which has the function to foster the solubility of the obtained polypropylene in the polymerization medium.
- a polymerization solvent selected from a paraff ⁇ nic, isoparaffinic, naphtenic, or aromatic hydrocarbon solvent, which has the function to foster the solubility of the obtained polypropylene in the polymerization medium.
- Suitable polymerization solvents are, for example, toluene, cyclohexane, hexane, heptane, octane, nonane, isooctane, ethylbenzene, isopentane and IsoparTM, which is a Cs-Cio hydrocarbon mixture.
- the polymerization of propylene is generally operated at a high temperature, generally in a range from 80 to 180 0 C, preferably from 90 to 130°, at a high pressure, generally in a range from 20 to 80 bar, preferably from 25 to 60 bar.
- the residence time of the liquid inside the reactor is generally comprised between 10 minutes and 90 minutes, preferably between 20 minutes and 60 minutes.
- a highly viscous polymeric solution is discharged from the polymerization reactor of step a): the viscosity of the polymeric solution is generally comprised between 1000 and 100000 centiPoises.
- the obtained polymeric solution is transferred to step b) of present invention aimed to deactivate the catalyst components contained in the polymer solution.
- the catalyst deactivation can be performed in one or more mixing tanks placed in series or, alternatively, in a single deactivation apparatus equipped with a sequence of more mixing stages.
- any of the deactivating compounds known in the art can be employed.
- Suitable deactivating compounds are water or organic compounds with a boiling point higher than 150 0 C and at least a hydroxy group. Examples of preferred deactivating compounds are water, propylenglycol, dipropylenglycol, glycerol; more preferably water is used as the deactivator.
- the deactivated polymer solution is discharged from the deactivation tank and is transferred by means of a volumetric pump to the successive separation step c), where unreacted monomers and the polymerization solvents, if present, are recovered and re-circulated to the polymerization reactor of step a).
- the polymeric solution discharged from the deactivation tank of step b) is transferred by means of a volumetric pump, preferably a screw pump, to the separation step c).
- the melt devolatilization technique of step c) requires the heating of the polymer solution at high values of temperature. Therefore, the polymeric solution is first pressurized by means of said screw pump to a pressure ranging from 40 to 100 bar, and then it is heated in one or more heat exchangers to raise its temperature to values comprised between 150 and 300 0 C, this value of temperature being bound to the volatility of the specific monomers and solvents to be recovered.
- One or more multi-tube heat exchangers, optionally containing static mixing elements inside each tube can be used to this purpose, as described in the Patent Application WO 04/000891 in the name of the same Applicant.
- the antioxidant compounds of the invention are added to the polymer solution along the line connecting the above screw pump to said first volatilization chamber of step c).
- a sequence of a first and a second volatilizer operating at a decreasing pressure is used in step c).
- the first volatilizer is operated at a pressure higher than the atmospheric pressure and the second one is operated under vacuum: by this technique a polymer melt substantially free of monomers and polymerization solvents is obtained at the outlet of the second volatilizer.
- Fig 1 shows a first embodiment of the process of the invention, where the antioxidant compounds are added to the polyolefin in correspondence of the first volatilization chamber of step c).
- Fig 2 shows a second embodiment of the process of the invention, where the antioxidant compounds are added to the polyolefin along the line connecting the catalyst deactivation tank to the first volatilization chamber.
- step a) of the invention is performed in a continuously stirred tank reactor 1.
- a transition metal compound, optionally supported on a carrier, an aluminum alkyl compound and optionally an electron donor compound are first pre-contacted in one or more pre-contacting pots (not shown) and then fed to the continuously stirred tank reactor 1 via line 2.
- a liquid stream containing liquid butene-1, and optionally olefin co monomers, is introduced into the polymerization reactor 1 via line 3.
- the olefin monomers coming from the monomer recovery section are recycled to the reactor 1 via line 4.
- a highly viscous solution of a polybutene-1 in butene-1 is discharged via line 5 from the reactor 1.
- Part of the polymeric solution is continuously recycled to the reactor 1 by a pump 6, which conveys the polymeric solution into a heat exchanger 7 and then, after suitable cooling, is recycled to the polymerization reactor 1 via line 8.
- the remaining part of polymeric solution discharged from the reactor 1 is conveyed to a deactivation tank 9, where is contacted with a catalyst deactivator, such as water, fed in a suitable amount to the tank 9 via line 10.
- a catalyst deactivator such as water
- the solution of polybutene-1 in butene-1 is pressurized in order to contrast the head loss along the successive heating stage.
- the polymer solution is pressurized and transferred by means of a screw pump
- the polymeric solution is pumped by the screw pump 11 to the inlet of a first heat exchanger
- the heat exchanger 12 is a multi-tube heat exchanger with static mixing elements inserted inside each tube: the heating fluid is preferably steam.
- the temperature of the polymeric solution is slowly increased without substantially to evaporate the liquid monomer with the purpose of decreasing considerably the viscosity of the polymer solution.
- the solution of polybutene-1 in butene-1 exits the heat exchanger 12 and enters a second heat exchanger 13, which is a multi-tube heat exchanger using a diathermic oil as the heating fluid.
- the polymer solution is heated in such a way that at the outlet of the heat exchanger 13 a two-phase mixture is obtained consisting substantially of: (1) polybutene melt containing entrapped butene-1 and (2) supercritical gaseous butene-1.
- the two-phase mixture coming from the heat exchanger 13 is then passed to the devolization step c) of present invention, carried out in a sequence of two volatilizers operating at decreasing pressures.
- the polymeric stream exiting from the heat exchanger 13 is introduced via line 14 at the top of a first volatilizer 15, which is operated at a temperature of 170-220 0 C and a pressure from 2 to 12 bar.
- the evaporated monomers are separated from the polymeric components: a polymer melt settles downwards at the bottom part of the volatilizer 15, while the evaporated monomers are realized away from the polymer, flowing upward as a gaseous stream.
- the gas phase exiting the top of the volatilizer 15 is transferred via line 16 to the monomer recovery section of the polymerization plant.
- the monomer recovery section comprises one or more distillation columns to separate the heavy components from the light components, a drying unit, and recycle lines of liquid monomers to the polymerization reactor.
- one or more antioxidant compounds in a liquid form are fed via line 17A to the top of the first volatilizer 15 and fall on the surface of the polymer melt which occupies the bottom portion of the volatilizer 15. Due to high turbulence existing inside the volatilizer, said antioxidant compounds are intimately mixed with the polymer melt.
- a polymer melt additivated with the antioxidant compounds of the present invention is withdrawn from the bottom of the first volatilizer 15 by means of a gear pump 18 and transferred via line 19 into a heat exchanger 20, which adjusts the temperature of the polymer melt at the values requested in the second volatilizer.
- the polymer melt exiting the heat exchanger 20 is introduced via line 21 at the top of a second volatilizer 22, which is operated at a temperature of 170-220 0 C and a pressure from 5 to 100 mbar. Said pressure values are maintained by means of the vacuum pump 23.
- the residual monomers are realized away from the polymer melt, which settles downwards at the bottom of the volatilizer 22.
- the unreacted monomers flow upward along the volatilizer 22: this gaseous stream collects at the top of the volatilizer 22 and is withdrawn by vacuum pump 23 and transferred via line 16 to the monomer recovery section.
- a polymer melt, further purified from the unreacted monomers is withdrawn by means of a gear pump 24 from the bottom of the second volatilizer 22 and transferred via line 25 into a static mixer 26 to be subjected to extrusion.
- the static mixer 26 has the function of mixing the polymer melt with suitable additives, such as nucleating agents, pigments, etc.
- a side-arm extruder (not shown) can be used for melting and mixing each other the additives used for the polyolef ⁇ n compounding.
- the compounded butene-1 (co)polymer exiting the static mixer 26 is then passed via line 27 to an underwater pelletizer 28, where it is cut into pellets by the action of rotating knife blades: the pellets are then cooled by means of cooling water.
- Fig 2 shows a second and alternative embodiment of the process of the invention, always referring to a solution polymerization of butene-1, as represented in Fig 1.
- the only difference in the process set-up of Fig 2 is due to the fact that the antioxidant compounds are added to the polyolefm solution via feed line 17B, which merges on the line connecting the catalyst deactivation tank 9 to the first volatilization chamber 15.
- the process of the invention is particularly suitable to be exploited in the production of homopolymers and copolymers based on ethylene, propylene and 1-butene, especially when the obtained polyolefm is characterized by bimodality, so as to be successfully employed in the production of pipes.
- the solution polymerization of olefins herewith described is not restricted to the use of any particular family of polymerization catalysts.
- the invention is useful in any exothermic polymerization reaction employing any catalyst, whether it is supported or unsupported, and regardless of whether it is in pre-polymerized form.
- the polymerization reaction can be carried out in the presence of highly active catalytic systems, such as Ziegler-Natta catalysts, single site catalysts, chromium-based catalysts.
- a Ziegler-Natta catalyst system comprises the catalysts obtained by the reaction of a transition metal compound of groups 4 to 10 of the Periodic Table of Elements (new notation) with an organometallic compound of group 1, 2, or 13 of the Periodic Table of element.
- the transition metal compound can be selected among compounds of Ti, V, Zr, Cr, and Hf.
- Preferred compounds are those of formula Ti(OR) n X y _ n in which n is comprised between 0 and y; y is the valence of titanium; X is halogen and R is a hydrocarbon group having 1-10 carbon atoms or a COR group.
- titanium compounds having at least one Ti-halogen bond such as titanium tetrahalides or halogenalcoholates.
- Preferred specific titanium compounds are TiCl 3 , TiCl 4 , Ti(OBu) 4 , Ti(OBu)Cl 3 , Ti(OBu) 2 Cl 2 , Ti(OBu) 3 Cl.
- Preferred organometallic compounds are the organo-Al compounds and in particular Al-alkyl compounds.
- the alkyl-Al compound is preferably chosen among the trialkyl aluminum compounds such as for example triethylaluminum, triisobutylaluminum, tri-n-butylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum. It is also possible to use alkylaluminum halides, alkylaluminum hydrides or alkylaluminum sesquichlorides such as AlEt 2 Cl and Al 2 Et 3 Cl 3 optionally in mixture with said trialkyl aluminum compounds.
- Particularly suitable high yield ZN catalysts are those wherein the titanium compound is supported on magnesium halide in active form which is preferably MgCl 2 in active form.
- magnesium halide in active form which is preferably MgCl 2 in active form.
- internal electron donor compounds can be supported on the MgCl 2 .
- esters can be selected among esters, ethers, amines, and ketones.
- compounds belonging to 1,3-diethers, cyclic ethers, phthalates, benzoates, acetates and succinates is preferred.
- an external electron-donor added to the aluminium alkyl co-catalyst component or to the polymerization reactor.
- These external electron donors can be selected among alcohols, glycols, esters, ketones, amines, amides, nitriles, alkoxysilanes and ethers.
- the electron donor compounds (ED) can be used alone or in mixture with each other.
- the ED compound is selected among aliphatic ethers, esters and alkoxysilanes.
- Preferred ethers are the C2-C20 aliphatic ethers and in particular the cyclic ethers preferably having 3-5 carbon atoms, such as tetrahydrofurane (THF), dioxane.
- esters are the alkyl esters of C1-C20 aliphatic carboxylic acids and in particular Cl-
- C8 alkyl esters of aliphatic mono carboxylic acids such as ethylacetate, methyl formiate, ethylformiate, methylacetate, propylacetate, i-propylacetate, n-butylacetate, i-butylacetate.
- the preferred alkoxysilanes are of formula R a 1 Rb 2 Si(OR 3 ) c , where a and b are integer from 0 to
- R 1 , R 2 , and R 3 are alkyl, cycloalkyl or aryl radicals with 1-18 carbon atoms. Particularly preferred are the silicon compounds in which a is 1, b is 1, c is 2, at least one of R 1 and R 2 is selected from branched alkyl, cycloalkyl or aryl groups with 3-10 carbon atoms and R 3 is a Ci-Cio alkyl group, in particular methyl.
- chromium compounds such as chromium oxide on silica, also known as Phillips catalysts.
- Suitable catalysts are single site catalysts, for instance metallocene-based catalyst systems which comprise: at least a transition metal compound containing at least one ⁇ bond; at least an alumoxane or a compound able to form an alkylmetallocene cation; and optionally an organo-aluminum compound.
- a preferred class of metal compounds containing at least one ⁇ bond are metallocene compounds belonging to the following formula (I):
- M is a transition metal belonging to group 4, 5 or to the lanthanide or actinide groups of the Periodic Table of the Elements; preferably M is zirconium, titanium or hafnium; the substituents X, equal to or different from each other, are monoanionic sigma ligands selected from the group consisting of hydrogen, halogen, R 6 , OR 6 , OCOR 6 , SR 6 , NR 6 2 and
- R 6 is a hydrocarbon radical containing from 1 to 40 carbon atoms; preferably, the substituents X are selected from the group consisting of -Cl, -Br, -Me, -Et, -n-Bu, -sec-Bu, -
- p is an integer equal to the oxidation state of the metal M minus 2;
- n is 0 or 1 ; when n is 0 the bridge L is not present;
- L is a divalent hydrocarbon moiety containing from 1 to 40 carbon atoms, optionally containing up to 5 silicon atoms, bridging Cp and A, preferably L is a divalent group (ZR 7 2 ) n ; Z being C, Si, and the R 7 groups, equal to or different from each other, being hydrogen or a hydrocarbon radical containing from 1 to 40 carbon atoms; more preferably L is selected from Si(CH 3 ) 2 , SiPh 2 , SiPhMe, SiMe(SiMe 3 ), CH 2 , (CH 2 ) 2 , (CH 2 ) 3 or C(CH 3 ) 2 ;
- Cp is a substituted or unsubstituted cyclopentadienyl group, optionally condensed to one or more substituted or unsubstituted, saturated, unsaturated or aromatic rings;
- A has the same meaning of Cp or it is a NR 7 , -O, S, moiety wherein R 7 is a hydrocarbon radical containing from 1 to 40 carbon atoms;
- Alumoxanes used as component b) are considered to be linear, branched or cyclic compounds containing at least one group of the type: wherein the substituents U, same or different, are defined above.
- n 1 is 0 or an integer of from 1 to 40 and where the U substituents, same or different, are hydrogen atoms, halogen atoms, Ci-C 2 o-alkyl, C 3 -C 2 o-cyclalkyl, C 6 -C 2 o-aryl, C 7 -C 2 o-alkylaryl or C 7 -C 2 o-arylalkyl radicals, optionally containing silicon or germanium atoms, with the proviso that at least one U is different from halogen, and j ranges from 0 to 1, being also a non-integer number; or alumoxanes of the formula: U (Al — O)n 2 can be used in the case of cyclic compounds, wherein n 2 is an integer from 2 to 40 and the U substituents are defined as above.
- Polydispersity index (P. L) this property is strictly connected with the molecular weight distribution of the polymer under examination. In particular it is inversely proportional to the creep resistance of the polymer in the molten state. Said resistance, called modulus separation at low modulus value, i.e. 500 Pa, was determined at a temperature of 200 0 C by using a parallel plates rheometer model RMS-800 marketed by RHEOMETRICS (USA), operating at an oscillation frequency which increases from 0.1 rad/s to 100 rad/s.
- the catalyst component contained 2.8 wt% of Ti and 12.3 wt% of phthalate.
- Example 1 Polymerization - step a) The liquid-phase polymerization of butene-1 is performed in two continuously stirred tank reactors (CSTR) placed in series in the presence of a Ziegler-Natta polymerization catalyst comprising: a solid catalyst component based on a Titanium compound, prepared as above indicated; triisobutylaluminum (TIBA) as a catalyst activator; thexyltrimethoxysilane as a donor compound for the stereoregularity control.
- the catalyst is fed exclusively to the first reactor of the two CSTR type reactors in series. Liquid butene-1 together with H 2 as a molecular weight regulator is continuously fed to the polymerization reactors.
- the polymerization conditions in the first and second reactors are reported in Table A, as well as the feeding ratio H2/C4H8.
- the PB-I solution is transferred to a deactivation apparatus for the killing of the catalyst residues: 2.0 kg/h of H 2 O, as the catalyst deactivator, is continuously fed to the top of the deactivation apparatus together with 26 t/h of polymeric solution.
- the polymeric solution is successively pressurized by means of a screw pump and is then subjected to heating in a sequence of two multi-tube heat exchangers.
- the first heat exchanger is provided with mixing rods inside each tube and uses steam at a temperature of 135°C as the heating fluid.
- the second heat exchanger uses a diathermic oil (MARLOTHERM N) at 260 0 C as the heating fluid.
- a mixture of polybutene-1 melt and gaseous butene-1 is obtained. Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar. The polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous butene-1 flows upward.
- antioxidant compounds are introduced into the first volatilizer.
- a mixture of IRGANOX® 1010 (70% wt) and IRGANOX® 1076 (30% wt) is fed to the bottom part of the first volatilizer. Said mixture is fed at a temperature of 75°C and a flow rate of 3.25 kg/h (corresponding to 500 ppm weight referred to the polymer).
- the PB-I melt is therefore discharged from the bottom of the first volatilizer and is introduced into a heat exchanger in order to raise its temperature up to the value requested into the second devolatilization chamber.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar. At the outlet of the second volatilizer the content of butene-1 in the polybutene-1 melt is measured obtaining a value of only 40 ppm weight.
- the polybutene- 1 melt is compounded in an extruder and finally, the compounded polybutene-1 melt is conveyed to an underwater pelletizer to be cut into pellets.
- the values of MIE and PI of the obtained PB-I pellets are reported in Table C, where MIE ⁇ and PI ⁇ refer to the polymer at the outlet of the polymerization step a), while MIE ⁇ and PI 1 ⁇ refer to the polymer pellets. It may be observed that the process of the invention ensures a limited and negligible MIE shift and PI shift.
- the polymeric solution is pressurized by means of a screw pump before to be subjected to heating in two multi-tube heat exchangers.
- antioxidant compounds are fed to the polymer solution along the line connecting the deactivation tank to the first volatilization chamber.
- a mixture of IRGANOX® 1010 (70% wt) and IRGANOX® 1076 (30% wt) is fed to the polymer solution downstream the screw pump and upstream the first heat exchanger. Said mixture is fed at a temperature of 75°C and a flow rate of 3.25 kg/h (500 ppm wt referred to the polymer).
- the temperature at the outlet of the second heat exchanger is 210 0 C and a mixture of polybutene-1 melt and gaseous butene-1 is obtained. Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar. The polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous butene-1 flows upward.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar. At the outlet of the second volatilizer the content of butene-1 in the polybutene-1 melt is measured obtaining a value of only 40 ppm weight.
- the polybutene- 1 melt is compounded in an extruder and finally, the compounded polybutene-1 melt is conveyed to an underwater pelletizer to be cut into pellets.
- Example 1 is subjected to catalyst deactivation as described in Example 1.
- the polymeric solution is pressurized by means of a screw pump before to be subjected to heating in the same multi-tube heat exchangers of example 1.
- the temperature at the outlet of the second heat exchanger is 210 0 C and a mixture of polybutene-1 melt and gaseous butene-1 is obtained. Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar. The polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous butene-1 flows upward.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar.
- the polybutene-1 melt is sent to an extruder, where it is additivated with a mixture of IRGANOX® 1010 (70% wt) and IRGANOX® 1076 (30% wt).
- Said mixture is fed at a flow rate of 3.25 kg/h.
- the catalyst is fed exclusively to the first reactor of the two CSTR type reactors in series.
- H 2 is used as a molecular weight regulator.
- the polymerization conditions in the first and second reactor are reported in Table B, as well as the feeding ratios ethylene/butene-1 and hydrogen/butene-1.
- a solution of random copolymer dissolved in butene-1 is continuously withdrawn from the second reactor at a flow rate of 26 t/h.
- the polymer concentration is of 21.5% by weight.
- a sample of polymeric solution is taken away at the outlet of the second reactor in order to evaluate the Melt Flow Index (MIE) and Polydispersity index (PI) of the obtained random copolymer. The values are shown in table C. Deactivation - step b)
- the polyolefin solution is transferred to the deactivation apparatus for the killing of the catalyst residues: an amount of 2.0 kg/h of H 2 O is continuously fed to the top of the deactivation apparatus.
- the polymeric solution is successively pressurized by means of a screw pump and is then subjected to heating in the sequence of two multi-tube heat exchangers.
- the temperature at the outlet of the second heat exchanger is 210 0 C and a mixture of polyolefin melt and gaseous monomers is obtained.
- Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar.
- the polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous monomers flow upward.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar. At the outlet of the second volatilizer the content of butene-1 in the polybutene-1 melt is measured obtaining a value of only 60 ppm weight.
- the polybutene- 1 melt is compounded in an extruder and finally, the compounded polybutene-1 melt is conveyed to an underwater pelletizer to be cut into pellets.
- the values of MIE and PI of the obtained PB-I pellets are reported in Table C.
- butene-1 random copolymer obtained by Example 4 is subjected to catalyst deactivation according to same modality described in Example 4. Once deactivated, the polyolefm solution is pressurized by means of the screw pump before to be subjected to heating in two multi-tube heat exchangers.
- the temperature at the outlet of the second heat exchanger is 210 0 C and a mixture of polyolefm melt and gaseous butene-1 is obtained.
- Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar.
- the polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous butene-1 flows upward.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar.
- the polybutene- 1 melt is compounded in an extruder and finally, the compounded polybutene-1 melt is conveyed to an underwater pelletizer to be cut into pellets.
- the values of MIE and PI of the obtained PB-I pellets are reported in Table C.
- Example 4 The same solution of butene-1 random copolymer obtained by Example 4 is subjected to catalyst deactivation according to same modality described in Example 4. Once deactivated, the polymeric solution is pressurized by means of a screw pump before to be subjected to heating in the same multi-tube heat exchangers of previous examples. At the outlet of the second heat exchanger a mixture of polybutene-1 melt and gaseous butene-1 is obtained. Said mixture is fed to the inlet of a first devolatilization chamber, operated a temperature of 210 0 C and a pressure of 7 bar. The polybutene-1 melt settles by gravity to the bottom of the chamber, while the gaseous butene-1 flows upward. The PB-I melt is therefore discharged from the bottom of the first volatilizer and is introduced into a heat exchanger in order to raise its temperature up to the value requested into the second devolatilization chamber.
- the second devolatilization chamber is operated under vacuum at 210 0 C and 25 mbar.
- the polybutene-1 melt is sent to an extruder, where it is additivated with a mixture of IRGANOX® 1010 (50% wt) and IRGANOX® 1076 (50% wt).
- the compounded polybutene-1 melt is conveyed to an underwater pelletizer to be cut into pellets.
Abstract
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US13/129,876 US8748522B2 (en) | 2008-11-25 | 2009-11-11 | Solution process for the olefins polymerization |
KR1020117014599A KR101672225B1 (en) | 2008-11-25 | 2009-11-11 | Solution process for the olefins polymerization |
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KR102458149B1 (en) * | 2020-10-13 | 2022-10-24 | 한화토탈에너지스 주식회사 | Arrangement for producing polyolefin elastomer |
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